CASE CX350C Tier 4 Crawler Excavator Service Repair Manual Instant Download

1
SERVICE MANUAL
Lep 84402827B EN
CX350C - CX370C Tier 4 Crawler Excavator
Issue date May 2011
2

• CRAWLER EXCAVATORS CX350C - CX370C TIER 4
  SERVICE MANUAL
• TABLE OF CONTENTS
• DIVISION/SECTION SECTION N
• GENERAL INFORMATION
• Safety, general information and standard torque
  data . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 1001
  Specifications . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . 1002A
• Main Equipment Table . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . .
  1002B
• Main Unit Weight . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . 1002C
• Maintenance Standards . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . 1002D
• Bolt Size and Torque Table. . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . .
  1002E
• Overall View . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . 1002F
• List of Special Tools. . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . 1003
• Fluid and Lubricants . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . 1004
• Conversion Table . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . 1005
• Abbreviations . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . 1900
• ENGINE
• Removal and Installation of Engine Assembly . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 2000 Removal
  and Installation of the Fuel Cooler Engine
  Inter-Cooler Radiator and Oil Cooler . . . . . .
  . . . . . 2001 Removal and Installation of Turbo
  Charger . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . 2004
• Removal and Installation of EGR Cooler and EGR
  Valve . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . 2005
• Removal and Installation of Engine Hood . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . 2006

Lep 84402827B EN May 2011
Copyright 2011 CNH France S.A. Printed in France
3

• TABLE OF CONTENTS
• DIVISION/SECTION SECTION N
• Data Reference Values . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . .
  4023K
• Electrical Wiring Diagram . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . .
  4040
• UNDERCARRIAGE
• Removal and Installation of Shoe Assembly . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 5001A
• Removal and Installation of Shoe Plate . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . 5001B
• Removal and Installation of Upper Roller . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . 5003A
• Assembly and Disassembly of Upper Roller . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 5003B
• Removal and Installation of Lower Roller . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . 5003C
• Assembly and Disassembly of Lower Roller . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 5003D
• Removal and Installation of the Sprocket . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . 5004
• Removal and Installation of Take-up Roller . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . 5005A
• Assembly and Disassembly of Take-up Roller . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 5005B
• Removal and Installation of Grease Cylinder. . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . 5005C
• Assembly and Disassembly of Grease Cylinder . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . 5005D
• DRIVE TRAIN
• Removal and Installation of Travel Motor . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . 6001

Lep 84402827B EN
Issued 2011-05
4
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• TABLE OF CONTENTS
• DIVISION/SECTION SECTION N
• Structure and Operation Explanation of Hydraulic
  Pump . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . 8030A
• Structure and Operation Explanation of Travel
  Motor . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 8030B
• Structure and Operation Explanation of Swing
  Motor . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 8030C
• Structure and Operation Explanation of Control
  Valve . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . 8030D
• 4 Stack Solenoid Valve Operation Explanation . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . 8030E
  Structure and Operation Explanation of Upper
  Pilot Valve (remote control valve) . . . . . . .
  . . . . . . . . . . 8030F Structure and
  Operation Explanation of Travel Pilot Valve
  (remote control valve). . . . . . . . . . . . . .
  . . . . 8030G Structure and Operation
  Explanation of Cushion Valve . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . 8030H
• UPPERSTRUCTURE
• Removal and Installation of Counterweight . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . 9002
• Removal and Installation of Bucket . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . 9003A
• Removal and Installation of Bucket Link . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . 9003B
• Removal and Installation of Arm . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . 9003C
• Removal and Installation of Boom . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . 9003D
• Removal and Installation of Operators Seat . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . 9004
• Removal and Installation of Cab Assembly . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . 9005A
• Removal and Installation of Wiper . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . . . 9005B
• Removal and Installation of Wiper Controller . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . 9005C
• Removal and Installation of Wiper Motor. . . . .
  . . . . . . . . . . . . . . . . . . . . . . . . .
  . . . . . . . . . . . . . . . . . . . 9005D

NOTE CNH France S.A. Company reserves the right
to make changes in the specification and design
of the machine without prior notice and without
incurring any obligation to modify units
previously sold. The description of the models
shown in this manual has been made in accordance
with the technical speci- fications known as of
the date of design of this document. All data
given in this manual is subject to production
variations. Dimensions and weights are provided
with approximate values and the machine fitting
shown in the illustrations may not correspond
with standard models. For precise information on
specific machine models and versions, please
contact your CASE dealer. Reproduction or
tranlation, even partial, is prohibited without
written authorization from CNH France SA Company.
Lep 84402827B EN May 2011
Copyright 2011 CNH France S.A. Printed in France
6
Section
1001
Safety, general information and standard torque
data
84402827B - May 2011
7
Safety, general information and standard torque
data
GENERAL INFORMATION CLEANING Clean all metal
parts except bearings, in a suitable cleaning
solvent or by steam cleaning. Do not use caustic
soda for steam cleaning. After cleaning, dry and
put oil on all parts. Clean oil passages with
compressed air. Clean bearings in a suitable
cleaning solvent, dry the bearings completely and
put oil on the bearings. INSPECTION Check all
parts when the parts are disassembled. Replace
all parts that have wear or damage. Small scoring
or grooves can be removed with a hone or crocus
cloth. Complete a visual inspection for
indications of wear, pitting and the replacement
of parts necessary to prevent early
failures. BEARINGS Check bearings for easy
action. If bearings have a loose fit or rough
action replace the bearing. Wash bearings with a
suitable cleaning solvent and permit to air dry.
DO NOT DRY BEARINGS WITH COMPRESSED AIR. NEEDLE
BEARINGS Before you press needle bearings in a
bore always remove any metal protrusions in the
bore or edge of the bore. Before you press
bearings into position put petroleum jelly on the
inside and outside diameter of the
bearings. GEARS Check all gears for wear and
damage. Replace gears that have wear or damage.
Oil seals, O-rings and gaskets. Always install
new oil seals, O-rings and gaskets. Put petroleum
jelly on seals and O-rings. SHAFTS Check all
shafts that have wear or damage. Check the
bearing and oil seal surfaces of the shafts for
damage. SERVICE PARTS Always install genuine
Case service parts. When ordering refer to
the Parts Catalogue for the correct part number
of the genuine Case replacement items. Failures
due to the use of other than genuine Case
replacement parts are not covered by warranty.
LUBRICATION Only use the oils and lubricants
specified in the Operators or Service
Manuals. Failures due to the use of non-specified
oils and lubricants are not covered by warranty.
84402827B - May 2011 1001-3
8
Safety, general information and standard torque
data Safety
This symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED. The message that follows the
symbol contains important information about
safety. Carefully read the message. Make sure
you fully understand the causes of possible
injury or death.
To prevent injury always follow the Warning,
Caution and Danger notes in this section and
throughout the manual. Put the warning tag shown
below on the key for the key switch when
servicing or repairing the machine. One warning
tag is supplied with each machine. Additional
tags are available from your service parts
supplier.
WARNING Read the operator's manual to familiarize
yourself with the correct control functions.
WARNING Operate the machine and equipment
controls from the seat position only. Any other
method could result in serious injury.
WARNING This is a one man machine, no riders
allowed.
WARNING Before starting engine, study Operators
Manual safety messages. Read all safety signs on
machine. Clear the area of other persons. Learn
and practice safe use of controls before
operating. It is your responsibility to
understand and follow manufacturers instructions
on machine operation, ser- vice and to observe
pertinent laws and regulations. Operator's and
Service Manuals may be obtained from your CASE
dealer.
WARNING If you wear clothing that is too loose or
do not use the correct safety equipment for your
job, you can be injured. Always wear clothing
that will not catch on objects. Extra safety
equipment that can be required includes hard hat,
safety shoes, ear protection, eye or face
protection, heavy gloves and reflector clothing.
WARNING When working in the area of the fan belt
with the engine running, avoid loose clothing if
possible, and use extreme caution.
WARNING When doing checks and tests on the
equipment hydraulics, follow the procedures as
they are written. DO NOT change the procedure.
WARNING When putting the hydraulic cylinders on
this machine through the necessary cycles to
check operation or to remove air from a circuit,
make sure all people are out of the way.
WARNING Use insulated gloves or mittens when
working with hot parts.
84402827B - May 2011 1001-4
9
Safety, general information and standard torque
data
WARNING Lower all attachments to the ground or
use stands to safely support the attachments
before you do any maintenance or service.
WARNING Pin sized and smaller streams of
hydraulic oil under pressure can penetrate the
skin and result in serious infection. If
hydraulic oil under pressure does penetrate the
skin, seek medical treatment immediately. Maintain
all hoses and tubes in good condition. Make
sure all connections are tight. Make a
replacement of any tube or hose that is damaged
or thought to be damaged. DO NOT use your hand to
check for leaks, use a piece of cardboard or wood.
WARNING When removing hardened pins such as a
pivot pin, or a hardened shaft, use a soft head
(brass or bronze) hammer or use a driver made
from brass or bronze and a steel head hammer.
WARNING When using a hammer to remove and install
pivot pins or separate parts using compressed air
or using a grinder, wear eye protection that
completely encloses the eyes (approved goggles or
other approved eye protectors).
WARNING Use suitable floor (service) jacks or
chain hoist to raise wheels or tracks off the
floor. Always block machine in place with
suitable safety stands.
WARNING When servicing or repairing the machine,
keep the shop floor and operator's compartment
and steps free of oil, water, grease, tools,
etc. Use an oil absorbing material and/or shop
cloths as required. Use safe practices at all
times.
WARNING Some components of this machine are very
heavy. Use suitable lifting equipment or
additional help as instructed in this Service
Manual.
WARNING Engine exhaust fumes can cause death. If
it is necessary to start the engine in a closed
place, remove the exhaust fumes from the area
with an exhaust pipe extension. Open the doors
and get outside air into the area.
WARNING When the battery electrolyte is frozen,
the battery can explode if (1), you try to charge
the battery, or (2), you try to jump start and
run the engine. To prevent the battery
electrolyte from freezing, try to keep the
battery at full charge. If you do not follow
these instructions, you or others in the area can
be injured.
84402827B - May 2011 1001-5
10
Section
2000
Removal and Installation of Engine Assembly
84402827B - May 2011
11
Removal and Installation of Engine Assembly
Removal of Engine Assembly

• WARNING
• Keep away from fire.
• Be sure to release hydraulic pressure before
  beginning work.
• The air conditioner circuit is filled with high-
  pressure gas, so there is the danger of gas
  spraying out when loosening lines.
• Do not use open flames and do not allow sparks
  near the battery.

• Drain the engine oil.(For details, see "Engine
  Oil Replacing".)
• Drain the coolant from the radiator.(For details,
  see
• "Removal and Installation of Radiator".)
• Remove the engine hood.(For details, see "Re-
  moval and Installation of Engine Hood".)
• Remove the hydraulic pump.(For details, see "Re-
• moval and Installation of Hydraulic Pump".)
• Use a wrench (13 mm) to remove the 3 bolts (1).

• CAUTION
• Be sure to stop the engine before beginning
  work.
• Be sure to inspect the wire rope and other
  lifting equipment before beginning work.
• Do not stand or pass under the suspended load.

• Items to prepare
• Wrenches (7 mm, 8 mm, 13 mm, 17 mm, 19 mm, 36
  mm)
• Box wrench (30 mm)
• Shackle (with the required lifting capacity) x 2
• Wire ropes (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Marking pen
• Cap
• Plug
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.

84402827B - May 2011 2000-3
12
Removal and Installation of Engine Assembly
6. Use a wrench (13 mm) to remove the 3 bolts
(1), and then remove the bracket (2).
8. Use a wrench (8 mm) to loosen the hose band
(1) on the radiator, and then remove the upper
hose (2).

• Remove the cushion seal on the side of the
  radiator, use a wrench (8 mm) to loosen the hose
  band (1) of the radiator, and then remove the
  lower hose (2).
• Use caps to cover the radiator and hoses to pre-
  vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
  drain the coolant.

7. Remove the fan guard (1).

• Use a wrench (13 mm) to loosen the line bolts (1)
  in 2 locations, and then remove the 2 lines (2)
  and (3) from the compressor.
• Always remove the low-pressure (suction side)
  line (2) first.
• Attach caps or plugs to the compressor and lines
  to prevent any entry of water, dust or dirt.
• Tightening torque for bolt installation 19.6 -
  24.5 Nm

84402827B - May 2011 2000-4
13
Removal and Installation of Engine Assembly

• Use a wrench (17 mm) to remove the 5 bolts (1),
  and then remove the under cover (2).
• Use caution when removing as the parts are
  heavy.
• Tightening torque for bolt installation 63.7 -
  73.5 Nm

• Prepare the waste oil can (1).
• Drain the engine oil before removing the engine
  oil hose.

• Use a wrench (8 mm) to loosen the hose band (1)
  on the inter cooler, and then remove the hose
  (2).
• Use caps to cover the lines and hoses to prevent
  the entry of water, dust or dirt.

• Use a wrench (36 mm) to remove the 2 engine oil
  remote hoses (1).
• Mark the engine and hoses so that the connectors
  match at the time of assembly.
• Attach caps or plugs to the engine and hoses to
  prevent any entry of water, dust or dirt.

84402827B - May 2011 2000-5
14
Removal and Installation of Engine Assembly
16. Use a wrench (17 mm) to remove the 5 bolts
(1), and then remove the under cover
(2). Tightening torque for bolt installation
63.7 - 73.5 Nm

• Clean the engine and hoses by spraying them with
  a parts cleaner to prevent scratches and pre-
  vent dirt from accumulating on the connectors.

17. Use a wrench (8 mm) to remove the 2 nuts (1),
and then remove the wiring (2) from the starter
motor.

• Use a wrench (17 mm) to remove the bolt (1), and
  then remove the battery cable (2) on the negative
  side.
• When removing the terminal and harness, secure
  them so that they do not interfere with the
  frame.
• Also, cover with a rubber cap to protect against
  sparks.

• Remove the hose band (1), and then remove the
  fuel hose (2).
• Attach caps or plugs to the engine and hoses to
  prevent any entry of water, dust or dirt.

84402827B - May 2011 2000-6
15
Removal and Installation of Engine Assembly

• Remove the hose band (1), and then remove the
  fuel hose (2).
• Attach caps or plugs to the engine and hoses to
  prevent any entry of water, dust or dirt.

22. Use a wrench (8 mm) to loosen the hose band
(1), and then remove the heater hose (2). Attach
caps or plugs to the engine and hoses to prevent
any entry of water, dust or dirt.

• Use a wrench (8 mm) to loosen the hose band (1),
  and then remove the heater hose (2).
• Attach caps or plugs to the engine and hoses to
  prevent any entry of water, dust or dirt.

20. Use a wrench (13 mm) to remove the 4 bolts
(1), and then remove the box cover (2).
21. Remove the connectors (1) in the box.

• Wrap the removed connectors in plastic after
  tying them together to prevent any entry of
  water, dust or dirt.

• Use a wrench (8 mm) to loosen the hose band (1),
  and then remove the radiator hose (2).
• Use caps to cover the lines and hoses to prevent
  any entry of water, dust or dirt.

84402827B - May 2011 2000-7
16
Removal and Installation of Engine Assembly

• Use a wrench (8 mm) to loosen the hose band (1),
  and then remove the air hose (2).
• Use caps to cover the lines and hoses to prevent
  any entry of water, dust or dirt.

27. Remove the connectors (1) from the alternator.

• 28. Remove the cap (1), use the wrench (10 mm) to
  remove the nut (2), and then remove the
  alternator wiring (3).
• Use a wrench (8 mm) to loosen the hose band (1),
  and then remove the air hose (2).
• Use caps to cover the lines and hoses to prevent
  any entry of water, dust or dirt.
• Tightening torque for bolt installation 8.8 -
  9.8 Nm

29. Install the 2 shackles (1), and then use the
wire rope (2) and liftcrane to secure the engine
main unit.
84402827B - May 2011 2000-8
17
Removal and Installation of Engine Assembly

• Use a box wrench (30 mm) to remove the 4 bolts
• from the mount.
• Tightening torque for bolt installation 289 -
  337 Nm

31. Use the wire rope (1) and liftcrane to lift
the engine main unit. Thoroughly check that the
location is safe before lowering the engine on
wood planks, etc.
84402827B - May 2011 2000-9
18
Removal and Installation of Engine Assembly
Installation of Engine Assembly

• Run the engine at no-load idling and check for
  any water or oil leaks.
• Attach the hydraulic pump, covers, and counter-
• weight.
• For details, see the individual explanations for
  each procedure.

1. To install the engine, perform the reverse of
the re- moval procedure. Tighten bolts being
installed to the specified torque. For bolts for
which the torque is not specified, see "Standard
Torque Data for Cap Screws and Nuts". After
installing the engine, resupply coolant and en-
gine oil, perform fuel line air bleeding, and
perform filling for the air conditioner gas. For
details, see the individual explanations for
each procedure.
84402827B - May 2011 2000-10
19
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Removal and Installation of Fuel Cooler
Removal of Fuel Cooler
1. Mark the fuel cooler and hoses (1) and (2) so
that the connectors match at the time of
assembly. Use pliers to loosen the hose bands (3)
and (4), and then remove the hoses. Fuel will
spill out, so place a drip pan directly below
the area. Attach caps or plugs to the fuel cooler
and hoses to prevent any entry of water, dust or
dirt.

• CAUTION
• Be sure to stop the engine before beginning
  work.
• As the fuel hose will be removed, strictly pro-
  hibit open flames.

• Items to prepare
• Wrench (13 mm)
• Screwdriver
• Pliers
• Marking pen
• Cap
• Plug
• Rag
• Cleaning fluid
• Drip pan

2. Use a wrench (13 mm) to remove the 4 bolts
(1), and then remove the fuel cooler (2).
Installation of Fuel Cooler To installation,
perform the reverse of the removal pro-
cedure. After connecting the hoses, carefully
check for any fuel leaks. Tighten bolts being
installed to the specified torque. For bolts for
which the torque is not specified, see "Stan-
dard Torque Data for Cap Screws and Nuts".
84402827B - May 2011 2001-3
20
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Removal and Installation of Engine Inter Cooler
Removal of Inter Cooler
1. Remove the fuel cooler.(For details, see
"Removal and Installation of Fuel Cooler".) Use
a wrench (13 mm) to remove the 4 bolts (1),
and then remove the bracket (2) from the fuel
cooler.

• CAUTION
• Be sure to stop the engine before beginning
  work.
• As the fuel hose will be removed, strictly pro-
  hibit open flames.

• Items to prepare
• Wrenches (8 mm, 13 mm)
• Flathead screwdriver
• Wire cutters
• Cap
• Rag
• Cleaning fluid

2. Use a wrench (8 mm) or flathead screwdriver to
loosen the hose bands (1) in the 2 locations,
and then remove the 2 hoses (2) and (3). Use
caps to cover the inter cooler and hoses to
pre- vent the entry of water, dust or dirt.
3. Use a wrench (13 mm) to remove the 4 bolts
(1), and then remove the inter cooler (2).
84402827B - May 2011 2001-4
21
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Installation of Inter Cooler To install, perform
the reverse of the removal procedure. Check for
any air leaks. Tighten bolts being installed to
the specified torque. For bolts for which the
torque is not specified, see "Stan- dard Torque
Data for Cap Screws and Nuts".
Removal and Installation of Radiator

• WARNING
• Do not remove the radiator cap when the ra-
  diator coolant temperature is high.
• Hot liquid could spray out.

• CAUTION
• Be sure to release hydraulic pressure before
  beginning work.
• Be sure to stop the engine before beginning
  work.
• Be sure to inspect the wire rope and other
  lifting equipment before beginning work.
• Do not stand or pass under the suspended load.

• Items to prepare
• Wrenches (8 mm, 14 mm, 19 mm)
• Box wrenches (8 mm, 10 mm)
• Pliers
• Shackle (with the required lifting capacity) x 2
• Wire ropes (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Caps
• Plugs
• Drain tank
• Drain hose
• Rag
• Cleaning fluid
• Wood planks, etc.

84402827B - May 2011 2001-5
22
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Removal of Radiator
4. Loosen the drain plug (1), and then drain the
coolant.
1. Use a wrench (19 mm) to remove the 5 bolts
(1), and then remove the under cover (2).

• Use a wrench (8 mm) to loosen the hose band (1),
  and then remove the hose (2).
• Use caps to cover the lines and hoses to prevent
  any entry of water, dust or dirt.

2. Install the drain hose (1), and then prepare
the drain tank (2).
3. To make it easier to drain the coolant, remove
the radiator cap (1).
6. Use a box wrench (13 mm) to remove the 1 nut
(1) and the 3 bolts (2) of the radiator cover.
84402827B - May 2011 2001-6
23
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
7. Use a wrench (8 mm) to loosen the hose band
(1) on the radiator, and then remove the upper
hose (2).

• Loosen the hose band (2), and then remove the
  hose (1) from the radiator cap.
• Attach caps or plugs to the hoses to prevent any
  entry of water, dust or dirt.

• Remove the cushion seal on the side of the
  radiator, use a wrench (8 mm) to loosen the hose
  band (1) of the radiator, and then remove the
  lower hose (2).
• Use caps to cover the radiator and hoses to pre-
  vent the entry of water, dust or dirt.
• Before removing the radiator hoses, completely
  drain the coolant.

11. Use a wrench (13 mm) to remove the 3 bolts
(1).
9. Remove the drain plug (1), loosen the hose
band (2), and then remove the hose (3).
84402827B - May 2011 2001-7
24
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
12. Use a wrench (13 mm) to remove the 3 bolts
(1), and then remove the bracket (2)
14. Remove the 2 butterfly bolts (1), and then
remove the front anti-insect net (2).
15. Install the 2 shackles (1) to the top of the
radiator, and then use the wire rope (2) and
liftcrane to lift the radiator.
13. Remove the fan guard (1).
84402827B - May 2011 2001-8
25
Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Installation of radiator To install, perform the
reverse of the removal procedure. Tighten bolts
being installed to the specified torque. For
bolts for which the torque is not specified, see
"Stan- dard Torque Data for Cap Screws and
Nuts". For details on the method for coolant
filling, see the (Ser- vice Text Procedures for
Replacing Consumable Parts Radiator Coolant
Replacement). Coolant capacity is 30 L. Finally,
check that the level of coolant is correct.
16. Lift the radiator together with the radiator
cover (2) until the fixtures (1) at the bottom
of the radiator become disconnected.
17. Thoroughly check that the location is safe
before lowering the radiator on square wooden
pieces. When laying down the radiator, be
careful not to bend or crush the bottom fixtures
(1).
84402827B - May 2011 2001-9
26
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Removal and installation of the fuel cooler
engine inter-cooler radiator and oil cooler
Removal and Installation of Oil Cooler
Removal of oil cooler

• Drain the hydraulic oil from the hydraulic oil
  tank. See "Draining Oil from Hydraulic Oil Tank"
  for de- tails of the procedure.
• Use a wrench (19 mm) to remove the 5 bolts (1),
• and then remove the under cover (2).

• WARNING
• Keep away from fire.

• CAUTION
• Be sure to stop the engine before beginning
  work.
• Be sure to inspect the wire rope and other
  lifting equipment before beginning work.
• Do not stand or pass under the suspended load.

• Items to prepare
• Wrenches (17 mm, 19 mm)
• Hexagon wrench (10 mm)
• Pliers
• Screwdriver
• Eyebolts (M12 x 2)
• Shackle (with the required lifting capacity) x 2
• Wire rope (with the required breaking load)
• Liftcrane (with the required lifting capacity)
• Caps
• Waste oil can
• Rag
• Cleaning fluid
• Wood planks, etc.

3. Prepare the waste oil can (1).
4. Remove the 4 butterfly bolts (1), and then
remove the anti-insect net (2).
84402827B - May 2011 2001-10
28
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